초록 ▼

An improved method is described for molding an article having a core of foam and a surface reinforced by fiberglass cloth or the like, which enables more rapid setup for molding and which creates a stronger and more uniform article. The method includes laying several layers of dry tissure paper on t

An improved method is described for molding an article having a core of foam and a surface reinforced by fiberglass cloth or the like, which enables more rapid setup for molding and which creates a stronger and more uniform article. The method includes laying several layers of dry tissure paper on the walls of the mold to form a first layer, laying dry fiberglass cloth over the first layer to create a second layer, and laying a sheet of dry tissue paper over the second layer to form a third layer. Foamable plastic is poured in the mold over the three layers and the mold is closed. As the plastic foams and expands, it first presses against the third layer to press it and the underlying first and second layers firmly against the mold walls to thereby position them evenly at the outer portion of the mold cavity. The foam material then penetrates the tissue paper of the third layer, the openings of the cloth of the second layer, and some of the layers of tissue paper of the first layer, before finally hardening. The outermost sheets of tissue paper facilitate release of the article from the mold, and also provide a conduit for the escape of gases during molding.

대표청구항 ▼

A method for constructing a surface-reinforced foam article comprising: laying a substantially dry porous but flow-through resistant first layer of flexible material consisting of substantially only fine fibers on the walls of a mold cavity, said mold cavity walls being devoid of any geletaneous coa

A method for constructing a surface-reinforced foam article comprising: laying a substantially dry porous but flow-through resistant first layer of flexible material consisting of substantially only fine fibers on the walls of a mold cavity, said mold cavity walls being devoid of any geletaneous coating that could penetrate through said first layer; laying a second layer of flexible easily permeated cloth material with openings, over the first layer, said second layer including fibers larger than those of said first layer; laying a substantially dry porous third layer of flow-through resistant flexible material over the second layer; and filling said mold cavity with foamable material which will form an expanding foaming liquid that solififies into a solid foam, and closing said mold; the amount of foamable material in said cavity being chosen, that the foaming foamable material permeates completely through said third layer and the openings of said second layer and permeates at substantially all areas of the mold, into said first layer before solidifying.